Integrated Circuits with Gate Stacks

ABSTRACT

Examples of an integrated circuit with a gate stack and a method for forming the integrated circuit are provided herein. In some examples, a method includes receiving a workpiece that includes: a pair of sidewall spacers disposed over a channel region, a gate dielectric disposed on the channel region and extending along a vertical surface of a first spacer of the pair of sidewall spacers, and a capping layer disposed on the high-k gate dielectric and extending along the vertical surface. A shaping feature is formed on the capping layer and the high-k gate dielectric. A first portion of the high-k gate dielectric and a first portion of the capping layer disposed between the shaping feature and the first spacer are removed to leave a second portion of the high-k gate dielectric and a second portion of the capping layer extending along the vertical surface.

PRIORITY DATA

The present application is a continuation application of U.S. patentapplication Ser. No. 15/812,350, filed Nov. 14, 2017, which claims thebenefit of U.S. Provisional Application No. 62/537,545, entitled“Integrated Circuits with Gate Stacks,” filed Jul. 27, 2017, each ofwhich is herein incorporated by reference in its entirety.

BACKGROUND

The semiconductor integrated circuit (IC) industry has experienced rapidgrowth. In the course of IC evolution, functional density (i.e., thenumber of interconnected devices per chip area) has generally increasedwhile geometry size (i.e., the smallest component (or line) that can becreated using a fabrication process) has decreased. This scaling downprocess generally provides benefits by increasing production efficiencyand lowering associated costs. However, such scaling down has also beenaccompanied by increased complexity in design and manufacturing ofdevices incorporating these ICs. Parallel advances in manufacturing haveallowed increasingly complex designs to be fabricated with precision andreliability.

For example, the materials used to form a gate stack of a transistorhave continued to evolve. At a high level, a gate stack may include aconductor and a gate dielectric that separates the conductor from achannel region of the transistor. Initially, polysilicon replacedaluminum as the conductor in the gate stack. However, polysilicon has ahigher impedance than many metals, and to improve performance, advancedfabrication processes have moved back to metal gates at the cost ofincreased complexity.

Another set of advances enabled the fabrication of three-dimensionaldesigns, such as a fin-like field effect transistor (FinFET). A FinFETmay be envisioned as a typical planar device extruded out of a substrateand into the gate. An exemplary FinFET is fabricated with a thin “fin”(or fin structure) extending up from a substrate. The channel region ofthe FET is formed in this vertical fin, and a gate is provided over(e.g., wrapping around) the channel region of the fin. Wrapping the gatearound the fin increases the contact area between the channel region andthe gate and allows the gate to control the channel from multiple sides.This can be leveraged in a number of way, and in some applications,FinFETs provide reduced short channel effects, reduced leakage, andhigher current flow. In other words, they may be faster, smaller, andmore efficient than planar devices.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is best understood from the following detaileddescription when read with the accompanying figures. It is emphasizedthat, in accordance with the standard practice in the industry, variousfeatures are not drawn to scale and are used for illustration purposesonly. In fact, the dimensions of the various features may be arbitrarilyincreased or reduced for clarity of discussion.

FIGS. 1A and 1B are flow diagrams of a method of fabricating a workpiecewith a replacement gate according to various aspects of the presentdisclosure.

FIG. 2 is a perspective view diagram of a workpiece undergoing a methodof fabrication according to various aspects of the present disclosure.

FIGS. 3, 5, 7, 9, 11, 13, 15, 17, and 19 are cross-sectional views of aworkpiece taken along a first cross-sectional plane at various points ina method of fabrication according to various aspects of the presentdisclosure.

FIGS. 4, 6, 8, 10, 12, 14, 16, 18, and 20 are cross-sectional views of aworkpiece taken along a second cross-sectional plane at various pointsin a method of fabrication according to various aspects of the presentdisclosure.

FIG. 21 is a cross-sectional view of a workpiece taken along a firstcross-sectional plane where a capping layer is recessed more than a gatedielectric layer according to various aspects of the present disclosure.

FIG. 22 is a cross-sectional view of a workpiece taken along a secondcross-sectional plane where a capping layer is recessed more than a gatedielectric layer according to various aspects of the present disclosure.

FIG. 23 is a cross-sectional view of a workpiece taken along a firstcross-sectional plane where a gate dielectric layer is recessed morethan a capping layer according to various aspects of the presentdisclosure.

FIG. 24 is a cross-sectional view of a workpiece taken along a secondcross-sectional plane where a gate dielectric layer is recessed morethan a capping layer according to various aspects of the presentdisclosure.

FIG. 25 is a cross-sectional view of a workpiece with an alternativegate stack configuration taken along a first cross-sectional planeaccording to various aspects of the present disclosure.

FIG. 26 is a cross-sectional view of a workpiece with an alternativegate stack configuration taken along a second cross-sectional planeaccording to various aspects of the present disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the disclosure.Specific examples of components and arrangements are described below tosimplify the present disclosure. These are, of course, merely examplesand are not intended to be limiting. For example, the formation of afirst feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations beyond the extentnoted.

Moreover, the formation of a feature on, connected to, and/or coupled toanother feature in the present disclosure that follows may includeembodiments in which the features are formed in direct contact, and mayalso include embodiments in which additional features may be formedinterposing the features, such that the features may not be in directcontact. In addition, spatially relative terms, for example, “lower,”“upper,” “horizontal,” “vertical,” “above,” “over,” “below,” “beneath,”“up,” “down,” “top,” “bottom,” etc. as well as derivatives thereof(e.g., “horizontally,” “downwardly,” “upwardly,” etc.) are used for easeof the present disclosure of one features relationship to anotherfeature. The spatially relative terms are intended to cover differentorientations of the device including the features.

At its most basic, a transistor may include a semiconductor doped toform source/drain features separated by a channel region. A gate stackis disposed on the channel region and includes a gate electrode and agate dielectric separating the gate electrode and the channel region.While any suitable gate dielectric may be used, many examples of thepresent disclosure use a high-k dielectric to reduce leakage current,reduce threshold voltage, and/or optimize the operation of thetransistor.

In some examples, a placeholder (e.g., polysilicon) gate is used duringa substantial amount of the fabrication process. The placeholder gate issubsequently replaced with functional gate components. However, formingthe functional components within the recess left by the placeholder gatehas proven challenging. It has been determined that, for example,forming the gate dielectric conformally along the entire sidewalls ofthe recess may increase parasitic capacitance, reduce the strength ofthe inversion charge, and increase the risk of voids and otherimperfections when depositing the gate material. As described below, insome examples, some or all of the gate dielectric is removed from thesidewalls of the recess. These examples may thereby provide improveddevice performance and reliability. However, unless otherwise noted, noembodiment is required to provide any particular advantage.

The techniques of the present disclosure may be used to form a varietyof planar and non-planar devices. Examples of a FinFET and a method offorming such are described with reference to FIGS. 1A-20. In thatregard, FIGS. lA and 1B are flow diagrams of a method 100 of fabricatinga workpiece 200 with a replacement gate according to various aspects ofthe present disclosure. Additional steps can be provided before, during,and after the method 100, and some of the steps described can bereplaced or eliminated for other embodiments of the method 100. FIG. 2is a perspective view diagram of the workpiece 200 undergoing the method100 of fabrication according to various aspects of the presentdisclosure. FIGS. 3, 5, 7, 9, 11, 13, 15, 17, and 19 are cross-sectionalviews of the workpiece 200 taken along a first cross-sectional plane(plane 202 of FIG. 2) at various points in the method 100 according tovarious aspects of the present disclosure. FIGS. 4, 6, 8, 10, 12, 14,16, 18, and 20 are cross-sectional views of the workpiece 200 takenalong a second cross-sectional plane (plane 204 of FIG. 2) at variouspoints in the method 100 according to various aspects of the presentdisclosure. FIGS. 2-20 have been simplified for the sake of clarity andto better illustrate the concepts of the present disclosure. Additionalfeatures may be incorporated into the workpiece 200, and some of thefeatures described below may be replaced or eliminated for otherembodiments of the workpiece 200.

Referring to block 102 of FIG. 1A and to FIG. 2, the workpiece 200 isreceived. The workpiece 200 includes a substrate 206 upon which devicesare to be formed. In various examples, the substrate 206 includes anelementary (single element) semiconductor, such as silicon or germaniumin a crystalline structure; a compound semiconductor, such as silicongermanium, silicon carbide, gallium arsenic, gallium phosphide, indiumphosphide, indium arsenide, and/or indium antimonide; anon-semiconductor material, such as soda-lime glass, fused silica, fusedquartz, and/or calcium fluoride (CaF2); and/or combinations thereof.

The substrate 206 may be uniform in composition or may include variouslayers, some of which may be selectively etched to form the fins. Thelayers may have similar or different compositions, and in variousembodiments, some substrate layers have non-uniform compositions toinduce device strain and thereby tune device performance. Examples oflayered substrates include silicon-on-insulator (SOI) substrates 206. Insome such examples, a layer of the substrate 206 may include aninsulator such as a semiconductor oxide, a semiconductor nitride, asemiconductor oxynitride, a semiconductor carbide, and/or other suitableinsulator materials.

In some examples, the devices to be formed on the substrate 206 extendout of the substrate 206. For example, FinFETs and/or other non-planardevices may be formed on device fins 208 disposed on the substrate 206.The device fins 208 are representative of any raised feature and includeFinFET device fins 208 as well as fins 208 for forming other raisedactive and passive devices upon the substrate 206. The fins 208 may beformed by etching portions of the substrate 206, by depositing variouslayers on the substrate 206 and etching the layers, and/or by othersuitable techniques. The fins 208 may be similar in composition to thesubstrate 206 or may be different therefrom. For example, in someembodiments, the substrate 206 may include primarily silicon, while thefins 208 include one or more layers that are primarily germanium or aSiGe compound semiconductor. In some embodiments, the substrate 206includes a SiGe compound semiconductor, and the fins 208 include one ormore layers that include a SiGe compound semiconductor with a differentratio of silicon to germanium.

The fins 208 may be physically and electrically separated from eachother by isolation features 210, such as a shallow trench isolationfeatures (STIs). In various examples, the isolation features 210 includedielectric materials such as semiconductor oxides, semiconductornitrides, semiconductor carbides, FluoroSilicate Glass (FSG), low-Kdielectric materials, and/or other suitable dielectric materials.

In some embodiments, a device fin 208 includes a transistor (e.g.,FinFET) formed on the fin 208 and defined by a pair of opposingsource/drain features 212 separated by a channel region 214. Thesource/drain features 212 may include a semiconductor (e.g., Si, Ge,SiGe, etc.) and one or more dopants, such as p-type dopants (e.g., boronor BF2) or n-type dopants (e.g., phosphorus or arsenic). Similarly, thechannel region 214 may include a semiconductor and one or more dopantsof the opposite type of those of the source/drain features 212.

The flow of carriers (electrons for an n-channel FinFET and holes for ap-channel FinFET) through the channel region 214 is controlled by avoltage applied to a gate stack 216 that is adjacent to and overwrappingthe channel region 214. The gate stack 216 is shown as translucent tobetter illustrate the underlying channel region 214 and is shown in moredetail in subsequent figures.

The workpiece 200 includes an Inter-Level Dielectric (ILD) layer 218disposed on the workpiece 200. The ILD layer 218 is shown as translucentto better illustrate the remainder of the workpiece 200. The ILD layer218 acts as an insulator that supports and isolates conductive traces ofan electrical multi-level interconnect structure that electricallyinterconnects elements of the workpiece 200, such as the source/drainfeatures 212 and the gate stack 216. The ILD layer 218 may comprise adielectric material (e.g., a semiconductor oxide, a semiconductornitride, a semiconductor oxynitride, a semiconductor carbide, etc.),Spin On Glass (SOG), FSG, phosphosilicate glass (PSG),borophosphosilicate glass (BPSG), Black Diamond® (Applied Materials ofSanta Clara, Calif.), Xerogel, Aerogel, amorphous fluorinated carbon,parylene, BCB, SILK® (Dow Chemical of Midland, Mich.), and/orcombinations thereof. The ILD layer 218 may be formed by any suitableprocess including Chemical Vapor Deposition (CVD), Physical VaporDeposition (PVD), spin-on deposition, and/or other suitable processes.

Referring to FIGS. 3 and 4, when the workpiece 200 is received, the gatestack 216 may include placeholder elements such as a placeholder gateelectrode 302. For example in a gate-last process, the placeholder gateelectrode 302 is used during some of the fabrication processes andsubsequently removed and replaced with one or more functional gatefeatures (e.g., gate electrode material, gate dielectric layer material,interfacial layer, etc.). This may be done when the functional featuresare sensitive to some fabrication processes, such as source/drainactivation annealing. The placeholder gate electrode 302 may includepolysilicon, dielectric material, and/or other suitable materials.

The gate stack 216 may also include a gate cap 304 disposed on a topsurface of the placeholder gate electrode 302. The gate cap 304 protectsthe placeholder gate electrode 302 during fabrication processes such asetching. In various examples, the gate cap 304 includes a dielectricmaterial (e.g., semiconductor oxides, semiconductor nitrides,semiconductor oxynitrides, semiconductor carbides, semiconductoroxycarbonitrides, etc.), and/or other suitable materials. In oneembodiment, the gate cap 304 includes silicon carbide.

The gate stack 216 may also include gate spacers 306 or sidewall spacersdisposed on the side surfaces of the placeholder gate electrode 302.Similar to the gate cap 304, the gate spacers 306 may protect theplaceholder gate electrode 302 and may be used when forming thesource/drain features 212 to control their offset and junction profile.In various examples, the gate spacers 306 include dielectric materials(e.g., semiconductor oxides, semiconductor nitrides, semiconductoroxynitrides, semiconductor carbides, semiconductor oxycarbonitrides,etc.), and/or other suitable materials, and are different in compositionand etchant sensitivity from the gate cap 304. In one embodiment, thegate spacers 306 each include one or more layers of silicon nitrideand/or silicon oxide.

In some embodiments, the workpiece 200 includes a Contact Etch StopLayer (CESL) 307 disposed alongside on the gate spacers 306. The CESL307 may surround and cover the source/drain features 212 and may bedisposed on top of those portions of the isolation features 210 that arenot covered by the gate stack 216. The CESL 307 may include a dielectric(e.g., a semiconductor oxide, a semiconductor nitride, a semiconductoroxynitride, a semiconductor carbide, etc.) or other suitable material,and in various embodiments, the CESL 307 includes SiN, SiO, and/or SiON.The ILD layer 218 may be disposed on the CESL 307.

Referring to block 104 of FIG. 1A and to FIGS. 5 and 6, an etchingprocess is used to remove the gate cap 304 and the placeholder gateelectrode 302. Removing the gate cap 304 and the placeholder gateelectrode 302 while leaving the gate spacers 306 and ILD layer 218defines a gate recess 502 within which to form functional structures ofthe gate stack 216. The bottom of the gate recess 502 may be defined bythe exposed channel region 214 and the isolation features 210, and thesides of the gate recess 502 may be defined by the gate spacers 306. Theetching processes may include any suitable etching technique such as wetetching, dry etching, Reactive Ion Etching (RIE), ashing, and/or otheretching methods. In some embodiments, the etching process includes dryetching using an oxygen-based etchant, a fluorine-based etchant, achlorine-based etchant, a bromine-based etchant, an iodine-basedetchant, other suitable etchant gases or plasmas, and/or combinationsthereof. In some embodiments, the etching process include a first stageusing a technique and etchant selected to selectively etch the gate cap304 without significant etching of the surrounding structures and asecond stage using a technique and etchant selected to selectively etchthe placeholder gate electrode 302 without significant etching of thesurrounding structures.

Referring to block 106 of FIG. 1A and to FIGS. 7 and 8, an interfaciallayer 702 is formed on the top and side surfaces of the fin 208 withinthe gate recess 502. The interfacial layer 702 may include any suitablematerial, such as a dielectric (e.g., a semiconductor oxide, asemiconductor nitride, a semiconductor oxynitride, a semiconductorcarbide, a semiconductor carboxynitride, etc.) or other suitablematerial. The interfacial layer 702 may be formed by chemical oxidation,thermal oxidation, CVD, Atomic Layer Deposition (ALD), and/or othersuitable techniques. Accordingly, in some embodiments, the interfaciallayer 702 includes silicon oxide and/or silicon-germanium oxide formedby thermal oxidation.

Referring to block 108 of FIG. 1A and referring still to FIGS. 7 and 8,a gate dielectric layer 704 is formed on the interfacial layer 702 andon the isolation feature 210 within the gate recess 502. When the gatedielectric layer 704 is formed, it may cover the interfacial layer 702and the isolation feature 210 within the recess 502. It may also extendvertically along the gate spacers 306 along the entire vertical sidesurfaces of the spacers 306. As explained in more detail below, thevertical portions of the gate dielectric layer 704 may be subsequentlyremoved to reduce coupling capacitance between the gate stack 216 andadjacent features.

Suitable materials for the gate dielectric layer 704 are commonlycharacterized by their dielectric constant (k) relative to siliconoxide. The gate dielectric layer 704 may include a high-k dielectricmaterial such as HfO₂, HfSiO, HfSiON, HfTaO, HfTiO, HfZrO, zirconiumoxide (ZrO₂), lanthanum oxide (La₂O₃), titanium oxide (TiO₂), yttriumoxide (Y₂O₃), strontium titanate (SrTiO₃), aluminum oxide, hafniumdioxide-alumina (HfO₂—Al₂O₃) alloy, other suitable high-k dielectricmaterials, and/or combinations thereof. In many applications, high-kdielectric materials reduce tunneling between the gate electrode and thechannel region 214, which may reduce leakage, avoid dielectricbreakdown, and increase transistor longevity. In some applications,because a high-k dielectric material may allow the gate dielectric layer704 to be thicker overall, it becomes easier to tune parameters ofindividual transistors such as operating or threshold voltages byadjusting the thickness of the gate dielectric layer 704.

However, the gate dielectric layer 704 is not limited to high-kdielectric materials. Additionally or in the alternative, the gatedielectric layer 704 may include other dielectrics such as silicondioxide, silicon nitride, silicon oxynitride, silicon carbide, amorphouscarbon, tetraethylorthosilicate (TEOS), other suitable dielectricmaterial, and/or combinations thereof.

The gate dielectric layer 704 may be formed by any suitable technique,such as CVD, ALD, Plasma Enhanced CVD (PE CVD), or Plasma Enhanced ALD(PEALD). The gate dielectric layer 704 may be formed to any suitablethickness 705, and in some examples, the gate dielectric layer 704 has athickness 705 of between about 0.1 nm and about 3 nm.

Referring to block 110 of FIG. 1A and referring still to FIGS. 7 and 8,a capping layer 706 is formed on the gate dielectric layer 704 withinthe gate recess 502. The capping layer 706 may cover the horizontalsurfaces of the gate dielectric layer 704 as well as the verticalsurfaces of the gate dielectric layer 704 that extend vertically alongthe gate spacers 306. The vertical portions of the capping layer 706 maybe subsequently removed along with the vertical portions of the gatedielectric layer 704.

The capping layer 706 may include any suitable conductive materialincluding metals (e.g., W, Al, Ta, Ti, Ni, Cu, Co, etc.), metalnitrides, and/or metal silicon nitrides, and may be deposited via CVD,ALD, PE CVD, PEALD, PVD, and/or other suitable deposition process. Invarious embodiments, the capping layer 706 includes TaSiN, TaN, or TiN.

Referring to block 112 of FIG. 1A and to FIGS. 9 and 10, aprofile-shaping feature 902 is formed on the workpiece. Specifically,the profile-shaping feature 902 fills the gate recess 502 and protectsunderlying portions of the gate dielectric layer 704 and the cappinglayer 706 within the recess 502 during a subsequent etching process. Theprofile-shaping feature 902 may be formed of any suitable material,which may be selected to have a different etchant sensitivity than thegate dielectric layer 704 and the capping layer 706. In variousexamples, the profile-shaping feature 902 includes a dielectric (e.g., asemiconductor oxide, a semiconductor nitride, a semiconductoroxynitride, a semiconductor carbide, a semiconductor carboxynitride,etc.), polysilicon, SOG, TEOS, Plasma Enhanced CVD oxide (PE-oxide),High-Aspect-Ratio-Process (HARP)-formed oxide, Bottom Anti-ReflectiveCoating (BARC), and/or other suitable materials. The profile-shapingfeature 902 may be deposited using any suitable process including ALD,CVD, HDP-CVD, PVD, spin-on deposition, and/or other suitable depositionprocesses.

Referring to block 114 of FIG. 1A and to FIGS. 11 and 12, theprofile-shaping feature 902 is etched back to expose the gate dielectriclayer 704 and the capping layer 706 within the recess 502. In variousexamples, the profile-shaping feature 902 is etched back using wetetching, dry etching, RIE, and/or Chemical MechanicalPlanarization/Polishing (CMP). In some examples, the etching of block114 is configured to leave a portion of the profile-shaping feature 902within the gate recess 502 in order to protect underlying portions ofthe gate dielectric layer 704 and the capping layer 706. The remainingportion of the profile-shaping feature 902 may have any suitable heightand/or aspect ratio. In various examples, the profile-shaping feature902 has an aspect ratio (height to width along the gate lengthdirection) between about 1:1 and about 2:1.

In some examples, the topmost surface of the profile-shaping feature 902is substantially coplanar with the topmost surface of the gate spacers306 that define the gate recess 502. In contrast, in some examples, theetching continues until the topmost surface of the profile-shapingfeature 902 is below the topmost surface of the gate spacers 306.

Referring to block 116 of FIG. 1B and to FIGS. 13 and 14, the cappinglayer 706 and the gate dielectric layer 704 are etched back. Within therecess 502, the etching removes at least some of the capping layer 706and the gate dielectric layer 704 that extend along the vertical surfaceof the gate spacers 306. In particular, the etching of block 116 may beconfigured to stop while the topmost surfaces of the capping layer 706and gate dielectric layer 704 adjacent the gate spacers 306 are stillabove the topmost surfaces of the capping layer 706 and the gatedielectric layer 704 underneath the profile-shaping feature 902 and inthe center of the recess 502. The remaining region 1302 of the cappinglayer 706 and gate dielectric layer 704 extending along the verticalsurfaces of the gate spacers 306 may have any suitable height 1304 asmeasured from the top surface of the gate dielectric layer 704underneath the profile-shaping feature 902.

In various examples, height 1304 is between about 1 nm and about 25 nm,and further examples where the height 1304 is about 0 are shown insubsequent figures below. Thus, in various examples, the ratio of theheight 1304 to the thickness 705 of the gate dielectric layer 704 may bebetween about 1:1 and about 10:1. Put another way, in various examples,the total gate height 1306 is between about 10 nm and about 200 nm, andthe ratio of the height 1304 of the region 1302 extending along thevertical surfaces of the gate spacers 306 to the total gate height 1306is about 1:4 or less. Accordingly, the majority of the vertical surfacesof the gate spacers 306 may be free of the gate dielectric layer 704.For comparison, in some examples, the gate length 1308 is between about10 nm and about 100 nm, and the ratio of the height 1304 of the region1302 to the gate length 1308 is about 1:4 or less. While FIG. 13illustrates examples where the remaining regions of the capping layer706 and the gate dielectric layer 704 have the same height 1304, furtherexamples are shown below where the capping layer 706 and gate dielectriclayer 704 are etched to different depths.

Removing the gate dielectric layer 704 and the capping layer 706 from atleast a portion of the gate spacers 306 may provide a number ofbenefits. For example, removing some of the gate dielectric layer 704and the capping layer 706 may reduce parasitic capacitances. In someexamples, capacitive coupling between the gate stack 216 and aneighboring conductor such as a source/drain contact is reduced. In someexamples, fringing capacitance of the gate stack 216 is reduced. Thesecapacitive effects may delay the rise and fall of voltage at the gateand at the source/drain contact. Accordingly, by reducing capacitivecoupling, the present structure may provide increased switching speed,decreased switching power consumption, and decreased coupling noise.

In some applications, the width of the gate recess 502 (in the gatelength direction 1308) provides a challenge when forming subsequent gatemetals in the recess. Removing some of the gate dielectric layer 704 andcapping layer 706 provides a wider recess 502 for these gate metalswhich may improve their uniformity by providing a wider gap to fill.Furthermore, because the gate dielectric layer 704 and the capping layer706 are removed from at least a portion of the gate spacers 306, thegate metals may be formed closer to the gate spacers 306. In some suchexamples, this configuration improves the strength and uniformity of theinversion charge created by the gate stack particularly at the boundaryof the channel region 214.

In various examples, the etching of the capping layer 706 and gatedielectric layer 704 includes wet etching, dry etching, RIE, and/orother suitable etching processes. In some examples, the etching processand chemicals are selected to avoid significant etching of the gatespacers 306 and the profile-shaping feature 902. The etching of block116 may include different etching processes and chemicals to target thecapping layer 706 and the gate dielectric layer 704 individually. In anexample, the etching includes a dry etching process using a chlorinebased etchant.

Referring to block 118 of FIG. 1B and to FIGS. 15 and 16, the remainderof the profile-shaping feature 902 is removed from the gate recess 502.The profile-shaping feature 902 may be removed using any suitableetching process such as wet etching, dry etching, RIE, and/or othersuitable etching processes, and the particular etching process may beselected to avoid significant etching of the capping layer 706, gatedielectric layer 704, gate spacers 306, and/or other components of theworkpiece 200. In some such examples, the profile-shaping feature 902 isremoved by ashing with an oxygen reactant.

In the steps that follow, the gate electrode is formed on the shapedcapping layer 706 and gate dielectric layer 704. Referring to block 120of FIG. 1B and to FIGS. 17 and 18, a barrier layer 1702 is formed on thecapping layer 706 and on the gate dielectric layer 704 within the gaterecess 502. At the sides of the recess 502, the barrier layer 1702 mayphysically contact the gate dielectric layer 704. The barrier layer 1702may also physically contact and extend along the vertical surfaces ofthe gate spacers 306. The barrier layer 1702 may contain any suitablematerial, such as W, Ti, TiN, Ru, or combinations thereof. Materials forthe barrier layer 1702 may be selected based on their resilience todiffusion into the capping layer 706, gate dielectric layer 704, and thegate spacers 306. The barrier layer 1702 may be deposited by anysuitable technique including ALD, CVD, PE CVD, PEALD, PVD (e.g.,sputtering), and/or combinations thereof. As noted above, becausevertical portions of the gate dielectric layer 704 and capping layer 706have been removed, much of the gate recess 502 is wider, which mayprovide more uniform deposition of the barrier layer 1702 and subsequentlayers.

Referring to block 122 of FIG. 1B and to FIGS. 17 and 18, one or morework function layers 1704 are formed within the gate recess 502 on thebarrier layer 1702. At the sides of the recess 502, the work functionlayers 1704 may be disposed on the top of the gate dielectric layer 704and capping layer 706 and may physically contact and extend along thevertical surfaces of the barrier layer 1702. Suitable work functionlayer 1704 materials include n-type and/or p-type work functionmaterials based on the type of device to which the gate stack 216corresponds. Exemplary p-type work function metals include TiN, TaN, Ru,Mo, Al, WN, ZrSi₂, MoSi₂, TaSi₂, NiSi₂, WN, other suitable p-type workfunction materials, and/or combinations thereof. Exemplary n-type workfunction metals include Ti, Ag, TaAl, TaAlC, TiAlN, TaC, TaCN, TaSiN,Mn, Zr, other suitable n-type work function materials, and/orcombinations thereof. The work function layer(s) 1704 may be depositedby any suitable technique including ALD, CVD, PE CVD, PEALD, PVD, and/orcombinations thereof. Because vertical portions of the gate dielectriclayer 704 and capping layer 706 have been removed, the work functionlayers 1704 may be wider than the capping layer 706 and wider than thecentral portion of the gate dielectric layer 704 with the substantiallyconsistent thickness.

Referring to block 124 of FIG. 1B and to FIGS. 17 and 18, a glue layer1706 may be formed within the recess 502 on the work function layer(s)1704. At the sides of the recess 502, the glue layer 1706 may physicallycontact and extend along the vertical surfaces of the work functionlayer(s) 1704. The glue layer 1706 may include any suitable material,such as metals (e.g., W, Al, Ta, Ti, Ni, Cu, Co, etc.), metal oxides,metal nitrides, and/or combinations thereof. Accordingly, in anembodiment, the glue layer 1706 includes TiN. The glue layer 1706 may bedeposited by any suitable technique including ALD, CVD, PE CVD, PEALD,PVD, and/or combinations thereof.

Referring to block 126 of FIG. 1B and to FIGS. 17 and 18, an electrodefill 1708 is formed within the recess 502 on the glue layer 1706. Theelectrode fill 1708 may include any suitable material including metals(e.g., W, Al, Ta, Ti, Ni, Cu, Co, etc.), metal oxides, metal nitridesand/or combinations thereof, and in an example, the electrode coreincludes tungsten (W). The electrode fill 1708 may be deposited by anysuitable technique including ALD, CVD, PE CVD, PEALD, PVD, and/orcombinations thereof.

Referring to block 128 of FIG. 1B and to FIGS. 19 and 20, a CMP processmay be performed to remove material (e.g., material of: the barrierlayer 1702, work function layers 1704, glue layer 1706, electrode fill1708, etc.) that is outside of the gate stack 216.

Referring to block 130 of FIG. 1B, the workpiece 200 is provided forfurther fabrication. In various examples, further fabrication includesforming contacts electrically coupled to the gate stack 216 and thesource/drain features 212, forming a remainder of an electricalinterconnect structure, dicing, packaging, and other fabricationprocesses.

As discussed above, the etching of the gate dielectric layer 704 and thecapping layer 706 in block 116 may result in the capping layer 706 andthe gate dielectric layer 704 having different heights. FIG. 21 is across-sectional view of a workpiece 2100 taken along a firstcross-sectional plane where a capping layer is recessed more than a gatedielectric layer according to various aspects of the present disclosure.FIG. 22 is a cross-sectional view of the workpiece taken along a secondcross-sectional plane where the capping layer is recessed more than thegate dielectric layer according to various aspects of the presentdisclosure. The workpiece 2100 may be formed using the method 100 ofFIGS. 1A and 1B and/or any other suitable technique. FIGS. 21 and 22have been simplified for the sake of clarity and to better illustratethe concepts of the present disclosure. Additional features may beincorporated into the workpiece 2100, and some of the features describedbelow may be replaced or eliminated for other embodiments of theworkpiece 2100.

The workpiece 2100 of FIGS. 21 and 22 is substantially similar toworkpiece 200 of FIGS. 2-20 in many respects, and includes a channelregion 214, gate spacers 306, an ILD layer 218, and an interfacial layer702, each substantially as described above. In the illustrated examples,after the etching of block 116, a remaining portion of the gatedielectric layer 704 adjacent a gate spacer 306 has a first height 2102as measured from the top surface of the portion of the gate dielectriclayer 704 away from the gate spacer 306. A remaining portion of thecapping layer 706 has a second height 2104 as measured from the topsurface of the portion of the gate dielectric layer 704 away from thegate spacer 306. By using different etching techniques (e.g., differentetching processes, different etching parameters, and/or differentetchants) for the gate dielectric layer 704 and capping layer 706 or byusing an etching technique with parameters and/or an etchant thatproduces a different etchant rate for the materials of the gatedielectric layer 704 and capping layer 706, a gate stack 216 is producedwhere the first height 2102 is greater than the second height 2104. Invarious examples, a ratio of the first height 2102 to the second height2104 is greater than about 1:1 and less than about 2:1. In some suchexamples, the first height 2102 of the gate dielectric layer 704 isbetween about 1 nm and about 25 nm, and may be between about 1 and about10 times the thickness of the gate dielectric layer 704. In some suchexamples, the ratio of the first height 2102 of the gate dielectriclayer 704 to the total gate height 1306 is about 1:4 or less.Accordingly, the majority of the vertical surfaces of the gate spacers306 may be free of the gate dielectric layer 704.

The barrier layer 1702, work function layer(s) 1704, glue layer 1706,and electrode fill 1708 are disposed one upon the other substantially asdescribed above.

In further examples, the height of the remaining the gate dielectriclayer 704 is less than that of the capping layer 706 after block 116.FIG. 23 is a cross-sectional view of a workpiece 2300 taken along afirst cross-sectional plane where a gate dielectric layer is recessedmore than a capping layer according to various aspects of the presentdisclosure. FIG. 24 is a cross-sectional view of the workpiece 2300taken along a second cross-sectional plane where the gate dielectriclayer is recessed more than the capping layer according to variousaspects of the present disclosure. The workpiece 2300 may be formedusing the method 100 of FIGS. 1A and 1B and/or any other suitabletechnique. FIGS. 23 and 24 have been simplified for the sake of clarityand to better illustrate the concepts of the present disclosure.Additional features may be incorporated into the workpiece 2300, andsome of the features described below may be replaced or eliminated forother embodiments of the workpiece 2300.

The workpiece 2300 of FIGS. 23 and 24 is substantially similar toworkpiece 200 of FIGS. 2-20 and workpiece 2100 of FIGS. 21 and 22 inmany respects and includes a channel region 214, gate spacers 306, anILD layer 218, an interfacial layer 702, a barrier layer 1702, workfunction layer(s) 1704, a glue layer 1706, and an electrode fill 1708,each substantially as described above.

In the illustrated examples, after the etching of block 116, a remainingportion of the gate dielectric layer 704 adjacent a gate spacer 306 hasa first height 2302 as measured from the top surface of the portion ofthe gate dielectric layer 704 away from the gate spacer 306. A remainingportion of the capping layer 706 has a second height 2304 as measuredfrom the top surface of the portion of the gate dielectric layer 704away from the gate spacer 306. By using different etching techniques(e.g., different etching processes, different etching parameters, and/ordifferent etchants) for the gate dielectric layer 704 and capping layer706 or by using an etching technique with parameters and/or an etchantthat produces a different etchant rate for the materials of the gatedielectric layer 704 and capping layer 706, a gate stack 216 is producedwhere the first height 2302 is less than the second height 2304. Invarious examples, a ratio of the first height 2302 to the second height2304 is less than 1:1 and greater than about 1:10. In some suchexamples, the first height 2302 of the gate dielectric layer 704 isbetween about 1 nm and about 25 nm, and may be between about 1 and about10 times the thickness of the gate dielectric layer 704. In some suchexamples, the ratio of the first height 2302 of the gate dielectriclayer 704 to the total gate height 1306 is about 1:4 or less.Accordingly, the majority of the vertical surfaces of the gate spacers306 may be free of the gate dielectric layer 704.

As discussed above, the etching of the gate dielectric layer 704 and thecapping layer 706 in block 116 may proceed until the height 1304 of theregion 1302 is zero or nearly zero. FIG. 25 is a cross-sectional view ofa workpiece 2500 with an alternative gate stack configuration takenalong a first cross-sectional plane according to various aspects of thepresent disclosure. FIG. 26 is a cross-sectional view of the workpiece2500 with an alternative gate stack configuration taken along a secondcross-sectional plane according to various aspects of the presentdisclosure. The workpiece 2500 may be formed using the method 100 ofFIGS. 1A and 1B and/or any other suitable technique. FIGS. 25 and 26have been simplified for the sake of clarity and to better illustratethe concepts of the present disclosure. Additional features may beincorporated into the workpiece 2500, and some of the features describedbelow may be replaced or eliminated for other embodiments of theworkpiece 2500.

The workpiece 2500 of FIGS. 25 and 26 is substantially similar toworkpiece 200 of FIGS. 2-20 in many respects, and includes a channelregion 214, gate spacers 306, an ILD layer 218, an interfacial layer702, a barrier layer 1702, work function layer(s) 1704, a glue layer1706, and an electrode fill 1708, each substantially as described above.

In the illustrated examples, after the etching of block 116, the topsurface of the gate dielectric layer 704 is substantially planar fromone gate spacer 306 to the opposing gate spacer 306, and the gatedielectric layer 704 has substantially consistent thickness throughout.In some examples, the gate dielectric layer 704 has a thickness 705 ofbetween about 0.1 nm and about 3nm. The top surface of the capping layer706 may also be substantially planar from one edge of the capping layer706 to the other, and the capping layer 706 may have substantiallyconsistent thickness throughout. In some examples, because the cappinglayer 706 is formed inside the gate dielectric layer 704 while the gatedielectric layer 704 has a U-shape, the capping layer 706 does notextend all the way to the gate spacers 306. The barrier layer 1702 isdisposed on the capping layer 706 and the gate dielectric layer 704 andphysically contacts the gate dielectric layer 704 near the gate spacers306.

Thus, the present disclosure provides examples of an integrated circuitwith a gate stack and a method for forming the integrated circuit. Insome examples, a method includes receiving a workpiece that includes: asubstrate; a fin extending from the substrate and having a channelregion; and a gate stack disposed over the channel region that includes:a pair of opposing gate spacers; a placeholder gate electrode disposedbetween the pair of opposing gate spacers; and a gate cap disposed onthe placeholder gate electrode and extending between the pair ofopposing gate spacers. The placeholder gate electrode and the gate capare removed to form a gate recess between the pair of opposing gatespacers. An interfacial layer is formed on the channel region within thegate recess between the pair of opposing gate spacers. A gate dielectricis formed on the interfacial layer within the gate recess between thepair of opposing gate spacers such that the gate dielectric extendsalong an entirety of a vertical sidewall of each of the pair of opposinggate spacers. A capping layer is formed on the gate dielectric withinthe gate recess between the pair of opposing gate spacers such that thecapping layer extends along an entirety of a vertical sidewall of thegate dielectric. A barrier feature is formed on the gate dielectric andthe capping layer within the gate recess. The barrier feature is removedsuch that a top surface of the barrier feature is coplanar with or belowa top of the pair of opposing gate spacers. A portion of each of thegate dielectric and the capping layer is removed from the verticalsidewall of each of the pair of opposing gate spacers. A remainder ofthe barrier feature is removed. A barrier layer is formed on the gatedielectric and the capping layer within the gate recess. A glue layer isformed on the barrier layer within the gate recess. An electrode fill isformed on the glue layer within the gate recess. A chemical mechanicalplanarization process is performed on the workpiece to remove a portionof each of the barrier layer, the glue layer, and the electrode fillthat extends beyond the gate recess, and the workpiece is provided forfurther fabrication.

In further examples, a device includes: a substrate; a fin extendingfrom the substrate that includes: a channel region; and a pair ofsource/drain features disposed on opposite sides of the channel region;and a gate stack disposed over the channel region that includes: a pairof opposing gate spacers; an interfacial layer disposed directly on thechannel region and extending between the pair of opposing gate spacers;a gate dielectric disposed directly on the interfacial layer and on avertical side surface of each of the pair of opposing gate spacers suchthat a first portion of each vertical side surface physically contactsthe gate dielectric and a second portion of each vertical side surfaceis free of the gate dielectric and the interfacial layer; a cappinglayer disposed directly on the gate dielectric; a barrier layer disposeddirectly on: the capping layer, the gate dielectric, the second portionof each vertical side surface; a work function layer disposed directlyon the barrier layer; a glue layer disposed directly on the workfunction layer; and an electrode fill disposed directly on the gluelayer.

In yet further examples, a device includes: a substrate; a fin extendingfrom the substrate that includes: a channel region; and a pair ofsource/drain features disposed on opposite sides of the channel region;and a gate stack disposed over the channel region that includes: a pairof opposing gate spacers; an interfacial layer disposed directly on thechannel region and extending between the pair of opposing gate spacers;a gate dielectric disposed directly on the interfacial layer and on avertical side surface of each of the pair of opposing gate spacers suchthat: a first portion of each vertical side surface physically contactsthe gate dielectric; a second portion of each vertical side surface isfree of the gate dielectric and the interfacial layer; and the gatedielectric has a substantially consistent thickness throughout; acapping layer disposed directly on the gate dielectric; a barrier layerdisposed directly on: the capping layer, the gate dielectric, the secondportion of each vertical side surface; a work function layer disposeddirectly on the barrier layer; a glue layer disposed directly on thework function layer; and an electrode fill disposed directly on the gluelayer.

In further examples, a method includes receiving a workpiece thatincludes: a substrate; a fin extending from the substrate and having achannel region; a pair of sidewall spacers disposed over the channelregion; a high-k gate dielectric disposed on the channel region betweenthe pair of sidewall spacers and extending along a vertical surface of afirst spacer of the pair of sidewall spacers; and a capping layerdisposed on the high-k gate dielectric between the pair of sidewallspacers and extending along the vertical surface. A shaping feature isformed on the capping layer and the high-k gate dielectric between thepair of sidewall spacers. A first portion of the high-k gate dielectricand a first portion of the capping layer disposed between the shapingfeature and the first spacer are removed to leave a second portion ofthe high-k gate dielectric and a second portion of the capping layerextending along the vertical surface. The shaping feature is removed,and a remainder of a gate on the high-k gate dielectric and the cappinglayer is formed. In some such examples, the removing of the firstportion of the high-k gate dielectric is such that a majority of thevertical surface is free of the high-k gate dielectric. In some suchexamples, the second portion of the high-k gate dielectric extends afirst distance above a top surface of a third portion of the high-k gatedielectric disposed away from the pair of sidewall spacer, and the firstdistance is less than one fourth of a height of the vertical surface ofthe first spacer. In some such examples, the second portion of thehigh-k gate dielectric extends a first distance above a top surface of athird portion of the high-k gate dielectric disposed away from the pairof sidewall spacers, and the first distance is between about equal toand about 10 times a thickness of the third portion of the high-k gatedielectric. In some such examples, the forming of the remainder of thegate includes forming a barrier layer on the high-k gate dielectric andthe capping layer such that the barrier layer directly physicallycontacts a top surface of the second portion of the high-k gatedielectric and a top surface of the second portion of the capping layer.In some such examples, a first top surface of the barrier layer on thesecond portion of the high-k gate dielectric is above a second topsurface of the barrier layer on a third portion of the high-k gatedielectric disposed away from the pair of sidewall spacers. In some suchexamples, the forming of the remainder of the gate further includesforming a work function layer on the barrier layer such that the workfunction layer is on the top surface of the second portion of the high-kgate dielectric and on the top surface of the second portion of thecapping layer. In some such examples, the work function layer is widerthan the capping layer.

In further examples, the method includes receiving a workpiece thatincludes: a channel region; a pair of opposing gate spacers disposedover the channel region with a gate recess defined therebetween; a gatedielectric on the channel region within the gate recess such that thegate dielectric extends along a vertical sidewall of the pair ofopposing gate spacers. A feature is formed on the gate dielectric withinthe gate recess. The feature is used to selectively remove a portion ofthe gate dielectric from the vertical sidewall of the pair of opposinggate spacers. The feature is removed, and a remainder of a gate on thegate dielectric on the gate dielectric. In some such examples, theworkpiece further includes a capping layer on the gate dielectric withinthe gate recess such that the capping layer extends along the verticalsidewall of the pair of opposing gate spacers, and the using of thefeature to selectively remove the portion of the gate dielectricincludes removing a portion of the capping layer from the verticalsidewall. In some such examples, the forming of the remainder of thegate includes forming a barrier layer on the gate dielectric such thatthe barrier layer directly physically contacts a top surface of the gatedielectric adjacent one of the pair of opposing gate spacers. In somesuch examples, the barrier layer directly physically contacts a portionof the vertical sidewall from which the gate dielectric is removed. Insome such examples, the forming of the remainder of the gate includesforming a work function layer on the top surface of the gate dielectricadjacent one of the pair of opposing gate spacers. In some suchexamples, the work function layer is wider than a capping layer disposedon the gate dielectric. In some such examples, a majority of thevertical sidewall of the pair of opposing gate spacers is free of thegate dielectric. In some such examples, a portion of the gate dielectricadjacent the vertical sidewall of the pair of opposing gate spacersextends a first height above another portion the gate dielectricdisposed away from the pair of opposing gate spacers, and the firstheight is less than one fourth of a height of the vertical sidewall. Insome such examples, a portion of the gate dielectric adjacent thevertical sidewall of the pair of opposing gate spacers extends a firstheight above another portion the gate dielectric disposed away from thepair of opposing gate spacers, and the first height is between aboutequal to and about 10 times a thickness of the another portion of thegate dielectric disposed away from the pair of opposing gate spacers.

In yet further examples, a method includes receiving a workpiece thatincludes a channel region and a pair of gate spacers disposed over thechannel region. A gate dielectric is formed between the pair of gatespacers and extending along a side surface of a first spacer of the pairof gate spacers. A capping layer is formed on the gate dielectricbetween the pair of gate spacers and extending along the side surface ofthe first spacer. A portion of the gate dielectric and a portion of thecapping layer is removed from between the feature and the side surfaceof the first spacer such that a remainder of the gate dielectric extendsa different height over a top surface of a portion of the gatedielectric away from the pair of gate spacers than a remainder of thecapping layer. In some such examples, the remainder of the gatedielectric extends to a first height over the top surface of the portionof the gate dielectric away from the pair of gate spacers, the remainderof the capping layer extends to a second height over the top surface ofthe portion of the gate dielectric away from the pair of gate spacers,and the removing is such that the first height is greater than thesecond height. In some such examples, the removing uses an etchantconfigured to etch a material of the gate dielectric at a different ratethan a material of the capping layer.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A device comprising: a first sidewall spacer andan opposing second sidewall spacer disposed over a substrate; a gatedielectric layer including a horizontal portion disposed over thesubstrate at a first height between the first sidewall spacer and thesecond sidewall spacer and a first vertical portion extending verticallyalong the first sidewall spacer to a second height that is greater thanthe first height; a capping layer disposed over the gate dielectriclayer and including a second vertical portion extending vertically alongthe first vertical portion of the gate dielectric layer to a thirdheight, the third height being less than a height of the first sidewallspacer; a barrier layer disposed over and physically contacting a topsurface of the second vertical portion of the capping layer and a topsurface of the first vertical portion of the gate dielectric layer; anda fill layer disposed over the barrier layer.
 2. The device of claim 1,wherein a ratio of the first height of the first vertical portion of thegate dielectric layer to a thickness of the horizontal portion of thegate dielectric layer is between about 1:1 and about 10:1, wherein aratio of the first height of the first vertical portion of the gatedielectric layer to the height of the first sidewall spacer is about 1:4or less, and wherein a ratio of the first height of the first verticalportion of the gate dielectric layer to a length measured from the firstsidewall spacer to the second sidewall spacer is about 1:4 or less. 3.The device of claim 1, wherein the third height is the same as thesecond height such the top surface of the second vertical portion of thecapping layer is level with the top surface of the first verticalportion of the gate dielectric layer.
 4. The device of claim 1, whereinthe third height is less than the second height.
 5. The device of claim1, wherein the third height is greater than the second height.
 6. Thedevice of claim 1, wherein the first vertical portion of the gatedielectric layer has a sidewall surface facing the second sidewallspacer, and wherein the second vertical portion of the capping layer andthe barrier layer both physically contact the sidewall surface of thefirst vertical portion of the gate dielectric layer.
 7. The device ofclaim 1, wherein the second vertical portion of the capping layer has asidewall surface facing the first sidewall spacer, and wherein the firstvertical portion of the gate dielectric layer and the barrier layer bothphysically contact the sidewall surface of the second vertical portionof the capping layer.
 8. A device comprising: a first sidewall spacerand an opposing second sidewall spacer disposed over a substrate; a gatedielectric layer disposed over the substrate and extending from thefirst sidewall spacer to the second sidewall spacer, the gate dielectriclayer having a top surface facing away from the substrate; a cappinglayer disposed over and physically contacting the top surface of thegate dielectric layer, the capping layer having a first sidewall surfacefacing the first sidewall spacer and an opposing second sidewall surfacefacing the second sidewall spacer; and a gate electrode disposed overand physically contacting the top surface of the gate dielectric layer,the first sidewall surface of the capping layer and the second sidewallsurface of the capping layer, the gate electrode additionally extendingfrom the first sidewall spacer to the second sidewall spacer.
 9. Thedevice of claim 8, wherein the gate electrode includes a barrier layerextending from the first sidewall spacer to the second sidewall spacer.10. The device of claim 8, wherein a height of the first sidewall spaceris between about 10 nm and about 200 nm, and wherein a length measuredfrom the first sidewall spacer to the second sidewall spacer is betweenabout 10 nm and about 100 nm.
 11. The device of claim 8, furthercomprising a fin structure disposed on the substrate, and wherein thegate dielectric layer, the capping layer and the gate electrode aredisposed over the fin structure.
 12. The device of claim 8, wherein thegate electrode further includes: a work function metal layer disposedover the barrier layer; and a fill layer disposed over the work functionmetal layer, and wherein a top surface of the barrier layer issubstantially coplanar with a top surface of the work function metallayer and a top surface of the fill layer.
 13. The device of claim 8,wherein the capping layer further includes a top surface extending fromthe first sidewall surface to the second sidewall surface, and whereinthe gate electrode physically contacts the top surface of the cappinglayer.
 14. The device of claim 8, wherein the first sidewall spacerextends a to a greater height over the substrate than the capping layer.15. A device comprising: a first sidewall spacer and an opposing secondsidewall spacer disposed over a substrate; a gate dielectric layerdisposed over the substrate and extending from the first sidewall spacerto the second sidewall spacer, the gate dielectric layer including afirst vertical portion extending vertically along the first sidewallspacer to a first height; a capping layer disposed over the gatedielectric layer, the capping layer including a second vertical portionextending vertically along the first vertical portion of the gatedielectric to a second height that is different than the first height;and a gate electrode disposed over the capping layer and extending to atleast one of the first and second sidewall spacers.
 16. The device ofclaim 15, wherein a ratio of the first height of the first verticalportion of the gate dielectric layer to the second height of the secondvertical portion of the capping layer is greater than about 1:1 and lessthan about 2:1.
 17. The device of claim 15, wherein a ratio of the firstheight of the first vertical portion of the gate dielectric layer to thesecond height of the second vertical portion of the capping layer isless than about 1:1 and greater than about 1:10.
 18. The device of claim15, wherein the gate electrode includes a barrier layer physicallycontacting both the first and second sidewall spacers.
 19. The device ofclaim 18, wherein the barrier layer is disposed over a top surface ofthe first sidewall spacer, the top surface facing away from thesubstrate.
 20. The device of claim 15, wherein the first height of thefirst vertical portion of the gate dielectric layer is between about 1nm and about 25 nm.